SANGOI SpA has an advanced consulting service regarding the optimisation of the mechanical piece from its prototyping to final production. Innovative solutions are studied and the most performing materials identified, and this is all supported by cost analyses. We carry out research on customer specifications in collaboration with selected science centres, laboratories and experienced mechanical designers. The service adopts precise standards for study and research with a guarantee of reliability of results and effectiveness of the solution.
The main areas of consulting include:
• design of mechanical pieces aimed at optimising work processes and saving production costs;
• identification of the most suitable materials for mechanical pieces;
• definition of technical parameters of materials to obtain certain performances from the piece;
• definition of parameters for the welding process and/or zinc coating of a piece;
• analysis of the critical points of a moulding process;
• failure analysis of steel products and pieces: analysis of rupture causes or non-compliance of a given piece.
Design of mechanical pieces designed to optimise manufacturing processes in order to save on production costs and study the optimal morphology.
Thanks to the collaboration with engineers, designers and research centres, we have developed a consulting service regarding the optimal design of the mechanical piece. This service aims to provide our clients with cost savings by identifying innovative solutions for the design of mechanical pieces to be assembled into a finished product. However, the service can also be extended to the design and prototyping of the entire finished product as well as the analysis of the morphology of the mechanical pieces with criteria that is not only dictated by the need for cost savings, functionality or feasibility. In consideration of increasing attention given to morphology (colour, tactile sensation and surface), this service also aims at examining piece aspects related to the perception of the final user. It is well known that this perception in addition to affecting the safety of use, it is important for acceptance and, therefore, the commercial success of the product. The engineers, designers and laboratories that we use are also very attentive to these aspects.
Identifying the most suitable materials for the production of mechanical pieces.
The extensive knowledge of the technical features of materials that make up the range of products together with the collaboration with leading metallurgical laboratories allow us to provide a reliable consulting service regarding the research of the most suitable materials to create a given mechanical pieces. Research is done with analytical methods and comparison tools that allow assessing, with measurable and objective criteria, the technical and economic implications of the possible materials that may be used.
Defining technical parameters of materials to obtain certain performances from the piece.
In addition to providing a service aimed at identifying the most suitable materials depending on the type of use and optimisation of costs, we can also define the detailed technical parameters suggested within the range provided for by the reference standard. Precisely defining these technical parameters helps ensure the work performance required from the piece to be created.
This service allows our clients to formulate the purchase specifications for the materials needed for their productions with enough details to prevent non-compliance and breakage.
Defining parameters for the welding process and/or zinc coating of a piece
Parameters of the welding process
Our service gives the possibility to prepare the WPS (Welding Procedure Specification) that defines the parameters to be complied with during the joint creation phase. The WPS identifies the welding details.
Some welding parameters that may be reported in a WPS include: Basic metal (CR ISO 15608 reference standard); Welding process (ISO 4063 reference standard); Joint features (UNI EN ISO 12345 reference standard); Filler materials; Welding and cutting gas; Welding position (ISO 6974 reference standard); Preheating, inter pass, post heating and PWHT; Electrical specifications; Welding technique.
Parameters for the zinc coating process
Our services give the possibility to define the zinc coating process parameters understood as:
- Defining the local minimum thickness of the coating based on the shape and thickness of the galvanized piece;
- Definition of procedures for sampling and testing of the coating in order to check the parameters defined and prescribed by the standards;
- Definition of how to perform the coating check (magnetic flow meter or chemical test to measure the weight of the coating);
- Identification of the sample area (representative of the product as a whole);
- Definition of number of samples to be examined;
- Definition of the number of items for which the thickness of the coating should be inspected and measured according to the size of the batch sent for galvanizing;
- Definition of the appearance and characteristics of the galvanizing;
- Definition of the quality of the zinc used for the coating (standard UNI EN ISO 1179);
- Definition of the area that the galvanizer can retouch; the reason, in general, for which the coating does not "stick" in certain small areas is due to some substances on the steel that the pickling could not eliminated. The touched up area is limited to 0.5% of the total area of steel and each retouching should not exceed 10 square centimetres.
Analysis of the critical points of a moulding process
- Definition of the process parameters (e.g. speed, temperature, etc.) to obtain a certain plastic deformation of the material through the moulding operation.
- Assessment of formability of a material through resistance measures (such as yield strength and breaking load);
- Assessment of the amount of plastic deformation tolerated before fracture;
- Anisotropy checks on the material to mould. The anisotropy, which is acquired during the thermo mechanical sheet metal production cycle, is one of the factors that can influence the forming and bendability of sheet metal.
Failure analysis of steel products and parts: analysis of rupture causes or non-compliance of a given piece
Examples of failure analysis include:
Analysis of defects caused by welding processes.
A hazard that is always present in fusion welds is the formation of cracks. Cracking is the greatest and most fearful fault of a welded joint. In fact, a crack can lead to fracturing and is likely to expand over and spread to the entire structure. Our consulting service can provide support in locating the crack (in the molten or heat affected area), define the type of crack and identify the cause of the crack.
Welding defects can also affect other operational aspects such as lack of penetration or fusion, stuck weld, solid and gaseous inclusions, excessive allowance, splashing and arc welding. Even for these types of problems we are able to provide support to analyse the causes of the defects and find ways to eliminate them.
A further example of defects of the welding processes can relate to deformations and residual stresses. Shrinking will occur during the cooling of molten zones and localised heating that occurs in fusion welds, and this could result in deformation of the work piece and residual stresses. In particular, the weld bead tends to shrink and narrow the section, and drags the surrounding parts with it. Even for these types of defects, it is possible to proceed with a detailed analysis of the location, cause and resolution.
Analysis of defects caused by zinc coating processes.
Analysis of reasons for which the zinc coating does not "stick".
Analysis of corrosion causes.
Analysis of rupture causes caused by a moulding process.